Abstract: A method of making prototype vehicles by first building a skeletal body of interlocking substantially rigid templates on a frame. The frame is built of tubing members and panels to precise specifications and is fitted with wheels to facilitate transporting the prototype. The templates are then traced on polystyrene foam pattern pieces which are sized to fill the spaces between the templates. The pattern pieces are then attached to the frame and shaped to the design contour surface. The surface is then removed to a predetermined depth in two steps and filled with a hardenable material, such as an epoxy resin based pliable material. After the hardenable material cures, the prototype is surface sanded, primed, painted and fitted with trim pieces and hardware.

Abstract: A method of making hard surface prototypes or styling concept models by assembling a contoured polystyrene foam pattern and applying an epoxy clay-like material in two steps to replace the surface of the polystyrene foam pattern. The polystyrene foam pattern is first assembled from blocks cut out to design drawing specifications. The pattern is then shaped to the design contour. The surface of the pattern is then grooved and the grooves filled with the epoxy clay. The remainder of the pattern surface is then removed and replaced by more epoxy clay which is then sanded and finished with paint and suitable trim pieces.